Miller BIG BLUE 500DX Owner's manual

BIG BLUE 500DX
Miller
Brand
Miller
Model
BIG BLUE 500DX
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
I
August
1996
Form:
OM-1
29
647Q
Effective
With
Serial
No.
KG191
348
OWNERS
MANUAL
~ll
''~7
~
Big
Bluefi
500DX
CC/DC
Welding
Generator
For
SMAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage
DC
Auxiliary
Power
Rating
Engine
Fuel
Capacity
500
A,
40
Volts
DC,
60%
Duty
Cycle
45600
95
Single-Phase,
3
kVNkW,
25
A,
120
V
AC,
60
Hz
Deutz
F3L-912
Air-Cooled,
Three-Cylinder,
41.5
HP
Diesel
Engine
23
gal
(87
L)
cover_om
4/95
-
ST-048
720-J
'
1996
MILLER
Electhc
Mfg.
Co.
PRINTED
IN
USA
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
LiMITED
WARRANTY
Subjecttotheterrns
end
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrsnts
to
its
original
reteil
purchsser
thet
new
MILLER
equipment
sold
sfter
the
effective
dste
of
this
limited
wsrrsnty
is
free
of
de
fects
in
materisl
snd
workmsnship
st
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANT1ES,
EXPRESS
OR
IMPUED,
INCLUDING
THE
WARRAN11ES
OF
MERCHANTABILiTY
AND
FIT
NESS.
Within
the
warrsnty
periods
listed
below,
MILLER
will
repair
or
replace
eny
wsr
ranted
perts
or
components
that
fsil
due
to
such
defects
in
msterisl
or
wortrmanship.
MILLER
must
be
notffied
in
writing
within
thirty
(30)
dsys
of
such
defect
or
fsilure,
st
which
time
MILLER
will
provide
instructions
on
the
warrsnty
claim
procedures
to
be
followed.
MILLER
ihall
honor
wsrrsnty
claims
on
wsrrented
equipment
listed
below
in
the
event
of
such
a
failure
within
the
wsrrsnty
time
periods.
All
wsrrsnty
time
periods
stsrt
on
the
dste
thst
the
equipment
was
delivered
to
the
originsl
retsil
purchaser;
or
one
yesr
eher
the
equipment
is
sent
to
s
North
American
distributor
or
eighteen
months
efter
the
equipment
is
sent
to
en
Intemational
distributor.
1.
5YeamPsrts3YesrsLsbor
Original
msin
power
rectifiers
Invertem
(input
end
output
rectifiers
only)
2.
3
Yeam
Pens
and
Lsbor
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
end
Automatic
Wire
Feeders
*
Inverter
Power
Supplies
Intetlitig
*
Robots
(1
yeer
lebor)
3.
2
Yeam
Pens
end
Lsbor
Engine
Driven
Welding
Generetors
(NOTE:
Engines
ere
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Yeer
Pens
end
Labor
*
Motor
Driven
Guns
Process
Controllers
IHPS
Power
Sources
Weter
Coolant
Systems
*
HF
Units
*
Grids
*
Spot
Welders
*
Load
Banks
*
SDX
Tmnsformem
*
Miller
Cyclomatic
Equipment
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecumseh
Engines
*
Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
am
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
fore
minimum
of
one
year
whichever
is
greater.)
5.
B
Months
Batteries
6.
90
Days
Pans
end
Labor
*
MIG
GunsPllG
Torches
APT,
aPCuT
&
PLAZCUT
Model Plasma
Cutting
Torches
*
Remote
Controls
Accessory
Kits
Replacement
Pans
MILLERS
True
Bluefi
Limited
Warranty
shall
not
apply
to:
1.
Items
fumished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contsctom
end
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
otherthan
MILLER,
orequip
ment
that
has
been
improperly
installed,
improperiy
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIAL)tNDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENt
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repairor
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chase
price
(leas
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costa
of
any
ldnd
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
UABLE
FOR
DIRECt
INDIRECt
SPECIAL,
INCIDENTALOR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PRORT),
WHETHER
BASED
ON
CON
TRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY.
-
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTA11ON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPUCA11ON,
OPERA11ON
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
ape
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
forcertain
additional
warranties
or
remedies
uther
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
I
This
limited
wsrrsnty
supersedes
all
previous
MILLER
warrsnties
snd
is
exclusive
with
no
other
gusrantees
or
warranties
expressed
or
implied.
.
J
}
I
WHO
DO
I
CONTACT?
1.
For
help,
ContaCt
your
distributor
For
additional
information,
such
as
TeChniCal
Manuals
(Service
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
Process
Handbooks
Users
Guides
Distributor
Directories
contact
your
distributor
To
file
a
claim
for
loss
or
damage
during
shipment,
contact
the
delivering
carrier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
Miller
Electric
Mfg.
Co.
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
l~
a
.
WRITE:
=
Miller
Electric
Mfg.
Co.
P.O.
BoX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
milleLwarl
3/96
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Engine
Hazards
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
3
1-5.
Principal
Safety
Standards
3
1-6.
EMF
Information
3
SECTION
2
DEFINITIONS
4
2-1.
Symbols
And
Definitions
4
SECTION
3INSTALLATION
5
3-1.
Installing
Welding
Generator
5
3-2.
Dimensions,
Weights,
And
Operating
Angles
5
3-3.
Activating
The
Dry
Charge
Battery
6
3-4.
Connecting
The
Battery
7
3-5.
Installing
Exhaust
Pipe
7
3-6.
Fuel
Consumption
7
3-7.
Engine
Prestart
Checks
8
3-8.
Weld
Output
Terminals
And
Cable
Sizes
9
3-9.
Installing
Ether
Cylinder
(Optional
Ether
Starting
Aid)
9
SECTION
4OPERATING
THE
WELDING
GENERATOR
10
4-1.
Duty
Cycle
And
Overheating
10
4-2.
Front
Panel
Controls
11
4-3.
Remote
A/V
Control
12
SECTION
5
OPERATING
AUXILIARY
EQUIPMENT
13
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
13
5-2.
Optional
Auxiliary
Power
Receptacles
14
5-3.
Connecting
Optional
Auxiliary
Power
Plant
15
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
16
6-1.
Routine
Maintenance
16
6-2.
Maintenance
Label
17
6-3.
Servicing
Air
Cleaner
18
6-4.
Servicing
Fuel
And
Lubrication
Systems
19
6-5.
Adjusting
Engine
Speed
20
6-6.
Servicing
Optional
Ether
Starting
Aid
20
6-7.
Checking
And
Replacing
Alternator
Belt
21
6-8.
Resetting
Fan
Belt
Safety
Shutdown
22
6-9.
Inspecting
And
Cleaning
Optional
Spark
Arrestor
Muffler
23
6-10.
Troubleshooting
23
SECTION
7
ELECTRICAL
DIAGRAM
25
SECTION
8
RUN-IN
PROCEDURE
26
8-1.
Wetstacking
26
8-2.
Run-In
Procedure
Using
Load
Bank
27
8-3.
Run-In
Procedure
Using
Resistance
Grid
28
SECTION
9
PARTS
LIST
30
OM-129
6470-
8)96
.
.
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
.
1-1.
Symbol
Usage
1-2.
Arc
Welding
Hazards
a
WARNING
safety_romi
4/95
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-5.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
irnproperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSI-IA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
oower
cord
around
wire
is
orooeriv
connected
to
around
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workaiece
or
worktable
as
near
the
weld
as
łractical.
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
,
~
This
group
of
syrnbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
__________________________________
actions
to
avoid
the
hazards.
A
Marks
a
special
safety
message.
~
Means
NOTE;
not
safety
related.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG
OR
SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
Arc
rays
from
the
welding
process
produce
intense
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
burn
eyes
and
skin.
Noise
from
some
3.
Wear
approved
safety
glasses
with
side
shields.
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
metal
or
slag.
and
glare;
warn
others
not
to
watch
the
arc.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if it
is
well
ventilated,
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
Welding
produces
fumes
and
gases.
Breathing
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
these
fumes
and
gases
can
be
hazardous
to
your
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
form
highly
toxic
and
irritating
gases.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-129
647
Page
1
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
bums.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.i
(see
Safety
Standards).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighteror
matches,
from
your
person
before
doing
any
welding.
1-3.
Engine
Hazards
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin.
Batteries
contain
acid
and
generate
explosive
gases.
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
skin.
It
is
best
to
check
coolant
level
when
engine
is
cold
to
avoid
scalding.
1.
Always
wear
a
face
shield
when
working
on a
battery.
2.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
4.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
5.
Observe
correct
polarity
(+
and
)
on
batteries
1.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and
3.
2.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
3.
Turn
cap
slightly
and
let
pressure
escape
slowly
before
completely
removing
cap.
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
produce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
explosion,
Engine
fuel
is
highly
flammable.
fire
or
2.
3.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
1.
Stop
eng
me
and
let
it
cool
off
before
checking
or
a
dding
fuel.
engine.
MOVING
PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch
loose
clothing.
4.
maintenance
and
troubleshooting
as
necessary.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
1.
Keep
all
securely
doors,
panels,
covers,
and
guards
closed
and
in
place.
5.
6.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
eng
me
before
installing
or
connecting
unit,
finished
and
before
starting
engine.
.
OM-129
647
Page
2
SECTION
2-
DEFINITLONS
2-1.
Symbols
And
Definitions
I:
Stop
Engine
Start
Engine
Ether
Starting
Aid
Engine
fi
/
..
Do
Not
Switch
While
Welding
I
+
I
Battery
(Engine)
Circuit
Breaker
Engine
Oil
4~
Check
lnjectors/
Pump
Check
Valve
Clearance
Fuel
Protective
Earth
(Ground)
._~_
Positive
Negative
~ti~j~J
Certified/Trained
Mechanic
/
.
Welding
Arc
A
Amperes
\/~
Volts
Panel/Local
~J
Remote
Read
Operators
Manual
j~
Temperature
Output
Alternating
Current
Q~
Time
h
Hours
Seconds
1
/\~
Single
Phase
3
~~s~f
Three
Phase
.
.
OM-129
647
Page
4
SECTION
3INSTALLATION
3-1.
Installing
Welding
Generator
Height
47-5/8
in
(1210
mm)
Width
31-1/4
in
(794
mm)
Depth
60-1/2
in
(1537
mm)
A
59-1/8
in
(1502
mm)
B
47-1/4
in
(1200
mm)
C
43-1/4
in
(1099
mm)
D
32-3/4
in
(832
mm)
E
24-15/16
in
(633
mm)
F
10-1/21n(267mm)
G
6-1/2
in
(165
mm)
H
2-7/8
in
(73
mm)
J
29-7/8
in
(759
mm)
K
11/16
in
(24
mm)
L
21~2
in
(17
mm)
Dia.
16
Holes
Weight
18
in
Location
18
in
Movement
Airflow
Clearance
A
Do
Not
Lift
Unit
From
End
18
in
(460
mm)
~OR~
18
in
(460
mm)
Grounding
OR
Electricallybondgeneratorframe
to
vehicle
frame
by
metal-to-metal
contact.
1
Generator
Base
2
Metal
Vehicle
Frame
3
Equipment
Grounding
Terminal
4
Grounding
Cable
Use
#10
AWG
or
larger
insulated
copper
wire.
A
If
unit
does
not
have
GFCI
receptacles,
use
GFCI
protected
extension
cord.
3-2.
Dimensions,
Weights,
And
Operating
Angles
installl
3196
Ref.
ST-800
652
I
Ref.
ST-800
477-A
/
ST-158
936-A
I
S-0854
L
/
Engine
End
Dimensions
A
Do
not
exceed
operating
angles
while
running
or
engine
damage
will
occur.
A
Do
not
move
or
operate
unit
where
it
could
tip.
Kil
I
_____
______
H
ST-158
699
angles_i
3/96
1898
lb
(861
kg)
OM-129
647
Page
5
3-3.
Activating
The
Dry
Charge
Battery
Remove
battery
from
unit.
1
Eye
Protection
Safety
Glasses
Or Face
Shield
2
Rubber
Gloves
3
Vent
Caps
4
Sulfuric
Acid
Electrolyte
(1.265
Specific
Gravity)
5
Well
Fill
each
cell
with
electrolyte
to
bottom
of
well
(maximum).
A
Do
not
overfill
battery
cells.
Wait
ten
minutes
and
check
elec
trolyte
level.
If
necessary,
add
elec
trolyte
to
raise
to
proper
level.
Reinstall
vent
caps.
6
Battery
Charger
A
Read
and
follow
all
instruc
tions
supplied
with
battery
charger.
Charge
batteryfor
12
minutes
at
30
amperes
or
30
minutes
at
5
am
peres.
Disconnect
charging
cables
and
install
battery.
g~
When
electrolyte
is
low,
add
only
distilled
water
to
cells
to
maintain
proper
level.
1
-~
2
.
0
-*
-~
6
5
A
For
30
Minutes
OR
30
A
For
12
Minutes
Tools
Needed:
I
drybatti
2/96
S-0886
OM-129
647
Page
6
3-4.
Connecting
The
Battery
3-6.
Fuel
Consumption
3-5.
Installing
Exhaust
Pipe
A
Stop
engine
and
let
cool.
A
Do
not
blow
exhaust
toward
air
cleaner
or
air
intake.
II!III~
Tools
Needed:
~
1/2
in
exh_pipe24/96ST-154
089-A/ST-154
611
IST-180933
The
curve
shows
typical
fuel
use
under
weld
or
power
loads.
a,
-j
7.57
1.70
2.00
6.82 1.46
1.75
5.67 1.25
1.50
4.73
1.04
1.25
3.78
0.83
1.00
2.84
0.82
0.75
1.98
0.40 0.50
0.95
0.21
0.25
0
~
-.-
0
50100150200250300350400450500
DC
WELD
AMPERES
AT
100%
DUTY
CYCLE
Ref.
ST-047
094-B
OM-129
647
Page
7
3-7.
Engine
Prestart
Checks
Check
all
fluids
daily.
Engine
must
be
cold
and
on a
level
surface.
Follow
run-in
procedure
in
engine
manual.
If
unburned
fuel
and
oil
collect
in
exhaust
pipe
during
run-in,
see
Section
8.
.
.
OM-129
647
Page
8
3-8.
Weld
Output
Terminals
And
Cable
Sizes
3-9.
Installing
Ether
Cylinder
(Optional
Ether
Starting
Aid
10
100%
Duty
Cycle
..~
~
~
~I
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
electronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
Weld
cable
size
(AW
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
I
100
ft
(30
m)
Or
Less
60r
1060%
60100%
Duty
Duty
Cycle Cycle
4
4
3
2
1
3
3
1
1/0
2/0
3
2
1/0
2/0
3/0
2
1
210 3/0
4/0
1
1/0
3/0
4/0
2-2/0
1/0
2/0
4/0
2-2/0 2-3/0
1/0
2/0
4/0
2-2/0
2-3/0
2/0 3/0
2-2/0
2-3/0
2-4/0
G)
is
based
on
either
a
4
volts
or
less
drop
or
a
current
density
of
at
least
300
circular
mils
per
ampere.
S-oooi-D
A
Stop
engine.
A
Improper
handling
or
expo
sure
to
ether
can
harm
your
health.
Follow
manufactur
ers
safety
instructions
on
cylinder.
A
Do
not
use
Ether
Starting
Aid
while
engine
is
running.
Open
side
door(s).
1
Ether
Cylinder
2
Nozzle
Remove
cover
and
clean
cylinder
nozzle.
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove
cap
and
clean
fitting.
Install
cylinder
on
fitting.
lighten
clamp.
lET
After
installing
cylindei
wait
at
least
10
minutes
before
using
to
let
ether
particles
settle
and
prevent
atomizer
plugging.
Put
cap
on
fitting
when
cylinder
is
removed.
etherl
7196-
ST-153
382-A
/
ST-i
80933
5
OM-129
647
Page
9
SECTION
4-
OPERATING
THE
WELDING
GENERATOR
.
.
4-1.
Duty
Cycle
And
Overheating
60%
Duty
Cycle
At
500
Amperes
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
6
Minutes
Welding
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
4
Minutes
Resting
RCED
cwP~
-
0)
Ui
Ui
0.
a
-I
Ui
C
S
S
Z
DUTY
CYCLE
40
WI0
70
0)00100
rdutyl
5/95
5B-089
697-B
OM-129
647
Page
10
4-2.
Front
Panel
Controls
1
Ampere
Range
Switch
A
Do
not
switch
under
load.
2
AmperageNoltage
Control
Control
adjusts
amperage
within
range
se
lected
by
Ampere
Range
switch.
Control
ad
justs
amperage
only
when
welding,
and
does
not
adjust
open-circuit
voltage.
Weld
output
would
be
233
A
DC
with
controls
set
as
shown
(50%
of
140
to
325
A).
3
Remote
AN
Control
Receptacle
And
Switch
(See
Section
4-3)
4
Manual
Stop
Control
5
EngineStart
Button
6
Ether
Starting
Aid
Switch
(Optional)
Push
switch
up
and
release
while
cranking
engine
to
release
ether.
A
Do
not
use
Ether
if
engine
is
running.
To
Start:
Press
button
and
use
Ether
switch
(if
necessary).
Release
button
when
engine
starts.
Do
not
crank
engine
while
engine
is
turning.
To
Stop:
Pull
control
out
and
hold.
Release
control
when
engine
stops.
7
DC
Ammeter
(Optional)
8
DC
Voltmeter
(Optional)
9
Oil
Pressure
Waming
Light
Light
goes
off
if
oil
pressure
is
too
low.
If
light
goes
oft,
stop
engine
and
check
oil
level.
10
Battery
Charging
Warning
Light
Light
goes
on
when
battery
is
not
charging.
Stop engine
and
check
engine
belt.
A
Stop
engine
and
fix
trouble
if
either
light
goes
on.
11
Engine
Hour
Meter
12
Polarity
Switch
(Optional)
.
ST-158
630-B
/
Ref.
ST-158
631
/
ST-i
80933
OM-129
647
Page
11
4-3.
Remote
NV
Control
.
.
ZNV
1
AN
Control
Switch
2
Use
switch
to
select
front
panel
or
remote
amperage
control.
2
Remote
AN
Control
Receptacle
RC3
Connect
optional
remote
control
to
RC3.
Example:
Combination
Remote
Amperage
Control
175-425
140-325
In
Example:
Range
=
140
to
325
A
Percentage
Of
Range
=
50%
Max
=
233
A
DC
(50%
of
140
to
325)
0
A/V
Set
Switches
Set
Range
Set
Percentage
Adjust
Optional
Remote
Control
Max
(233
A
DC)
Min(100ADC)
S-0774
/
Ref.
ST-i
80
933
OM-129
647
Page
12
SECTION
5-
OPERATING
AUXILIARY
EQUIPMENT
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
!
!l~~~f
~i~1
~
I
A
If
unit
does
not
have
GFCI
t
I
I
receptacles,
use
GFCI-pro
_____________________________
tected
extension
cord.
1
120V
15AAC
Receptacle
RC2
2
240
V
15
A
AC
Receptacle
RC1
Receptacles
supply
60
Hz
single-
phase
power
at
weld/power
speed.
3
Circuit
Breakers
CB1
And
CB2
CB1
and
CB2
protect
Rd
and
RC2
from
overload.
If
CB1
or
CB2
opens,
Rd
and
one
half
of
RC2
does
not
work.
120
volts
may
still
be
present
at
RC1.
Press
button
to
reset
breaker.
g~
If
a
circuit
breaker
continues
to
open,
contact
Factory
Autho
rized
Service
Agent.
Maximum
output
from
each
duplex
receptacle
is
1.8
kVAJkW,
and
3
kVNkW
from
all
receptacles.
~
Auxiliary
power
is
not
affected
by
weld
output.
3~
EXAMPLE:
If
10
A
is
drawn
from
RC1,
only
5
A
is
available
at
RC2:
(240
V
x
10
A)
+
(120
V
x
5
A)
=
3.0
kVA/kW
Ref.
ST-leo
933
OM-129
647
Page
13
5-2.
Optional
Auxiliary
Power
Receptacles
OM-129
647
Page
14
4
2
3
5
If
a
circuit
breakercontinues
to
open,
contact
Factory
Autho
nzed
Service
Agent.
GFCI
Receptacle
Option
1
120V15AACGFCI
Receptacle
GFCI1
Auxiliary
power
output
and
circuit
breaker
protec~on
is
the
same
as
standard
receptacles
(see
Section
5-1)
If
a
ground
fault
is
detected,
GFCI
Reset
button
pops
out
and
receptacle
does
not
work.
Check
for
faulty
tools
plugged
in
receptacle.
Press
button
to
reset.
~
At
least
once
a
month,
run
en
gine
at
weld/power
speed
and
press
test
button
to
verify
GFCI
is
working
properly.
Australian
And
South
African
Receptacle
Options
2
240V
1OAAC
Australian
Receptacle
RC1
3
24OVoltl3AACSouth
African
Receptacle
RC1
RC1
supplies
60
Hz
single-phase
power
at
weld/power
speed.
Maxi
mum
output
from
receptacle
is
3
kVNkW.
4
Circuit
Breaker
CB1
CB1
protects
RC1
from
overload,
If
CB1
opens,
RC1
does
not
work.
Press
button
to
reset
breaker.
British
Receptacle
Option
5
240
Volt
13
A
AC
British
Receptacles
RC1
And
RC2
RC1
and
RC2
supply
60Hz
single-
phase
power
at
weld/power
speed.
Maximum
combined
output
of
both
receptacle
is
3
kVNkW.
6
Circuit
Breaker
CB1
CB1
protects
RC1
and
RC2
from
overload.
If
CB1
opens,
the
recep
tacles
do
not
work.
Press
button
to
reset
breaker.
A
If
unit
does
not
have
GFCI
receptacles,
use
GFCI-pro
tected
extension
cord.
~
Auxiliary
power
is
not
affected
by
weld
output.
.
4
6
Ref.
ST-isO
933/Ref.
ST-182
266
5-3.
Connecting
Optional
Auxiliary
Power
Plant
Tools
Needed:
A
Stop
engine.
A
Power
and
weld
outputs
are
live
at
the
same
time.
Discon
nect
or
insulate
unused
cables.
Have
qualified
person
install
according
to
circuit
diagram
and
Auxiliary
Power
Guidelines
Booklet
(M176
712).
Remove
junction
box
cover.
1
Lead
93
2
Lead
92
3
Lead
91
4
Lead
90
(Neutral)
5
Lead
42
(Circuit
Grounding
Lead)
Lead
42
connects
to
front
panel
Ground
stud.
6
Grounding
Terminal
7
JumperLead42
8
Isolated
Neutral
Terminal
Jumper
42
is
connected
to
lead
90
at
factory.
Jumper
42
may
be
dis
connected
from
neutral
to
meet
applicable
electrical
codes.
9
User-Supplied
Leads
10
Load
Terminals
Connect
leads
to
terminals.
11
Fuses
Fl,
F2,
And
F3
Fl,
F2,
and
F3
protect
each
load
line
from
overload.
AC
~
Output
Single
Phase
1
r~j
Three
Phase
3(\J
Volts
120/240
240
Amps
31
24
KVA/KW
7.5
10
Frequency
60
Hz
Engine
Speed
1850
RPM
Max.
Fuse
Size
35
Amperes
93
91
90
92
Ref.
5-180
187
OM-129
647
Page
15
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
fi8h
Recycle
engine
fluids.
A
Stop
engine
before
maintaining.
U~
See
also
Engine
Manual
and
Mainte
nance
Label.
Service
engine
more
often
during
severe
conditions.
.
50h
/
200h
~c3#
Change
Oil.
See
Section
6-4.
250h
500h
4
l000h
I
OM-129
647
Page
16
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Miller BIG BLUE 500DX Owner's manual

BIG BLUE 500DX
Miller
Brand
Miller
Model
BIG BLUE 500DX
Category
Welding System
Type
Owner's manual
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